US4241585A

US4241585A - Method of operating a vapor generating system having integral separators and a constant pressure furnace circuitry

Info

Publication number: US4241585A
Application number: US05/896,524
Authority: US
Inventors: Walter P. Gorzegno
Original assignee: Foster Wheeler Energy Corp
Current assignee: Foster Wheeler Energy Corp
Priority date: 1978-04-14
Filing date: 1978-04-14
Publication date: 1980-12-30
Anticipated expiration: 1998-04-14
Also published as: JPS6157444B2; JPS54138935A

Abstract

A method of operating a vapor generating system for use in a power plant having a turbine control valve means, steam turbine and condenser connected in a main flow circuit in a series flow relationship, in which fluid is passed through a vapor generator furnace section at a predetermined flow rate and a firing rate is established in the furnace section to apply heat to the fluid while controlling the pressure of the fluid as it exits from the furnace section. The turbine control valve means are fixed at a predetermined percent open. The firing rate is increased to a predetermined percent of full load firing rate until the firing rate approximately corresponds to the percentage of full load flow rate of the fluid. The fluid flow rate is then increased together with the firing rate in a manner to increase the throttle pressure of the fluid to the turbine in proportion to load demand on the turbine until the load on the turbine reaches a predetermined percentage of full load.

Description

BACKGROUND OF THE INVENTION

This invention relates to a method for operating a vapor generator and in particular to a method for operating a subcritical or supercritical, once-through vapor generator having integral separators and a constant pressure furnace circuitry.

In general, a once-through vapor generator operates to circulate a pressurized fluid, usually water, through a vapor generating section and a superheating section to convert the water to vapor. In these arrangements, the water entering the unit makes a single pass through the circuitry and discharges through the superheating section outlet of the unit as superheated vapor for use in driving a turbine, or the like.

Although these arrangements provide several improvements over conventional drum-type boilers, some problems have arisen in connection with starting up the generators, usually stemming from fluid at an undesirable quantity or condition being passed to the components of the system, resulting in excessive thermal losses, as well as mismatching of the throttle steam to the turbine inlet causing a decrease in turbine component life.

Earlier attempts to solve some of these problems included arrangements providing bypass circuitry for a portion of the fluid at a point in the flow circuitry between the vapor generating and superheating sections and/or between the superheating section and the turbine during startup to precool a portion of the system yet avoid the possibility of fluid at an undesirable quantity or condition being passed to the turbine. However, these arrangements resulted in very poor heat recovery and, therefore, operated at a reduced thermal efficiency and, moreover, resulted in relatively unsuitable turbine throttle vapor conditions for rolling and bringing the turbine up to speed prior to loading.

Attempts to alleviate the latter problems included installing a division valve in the main flow path to divert flow to a bypass circuit including a flash tank separator located between the vapor generating section and the superheating section, or between a primary and finishing superheater in the superheating section. In these arrangements, the flash vapor from the separator is furnished to the superheating section or to the finishing superheater, and the drains from the separator are passed to a deaerator and/or high pressure heater and/or condenser. However, in these systems, the separator could often accommodate only a limited pressure, which was considerably less than the full operating pressure of the main pressure parts. Therefore, after startup, when turbine demands approached pressures exceeding the design pressure of the separator, the separator had to be switched out of operation and flow to the turbine supplied directly from the main flow line upstream of the flash tank. However, this switch of flow often caused control difficulties and, in addition, caused a drop in enthalpy at the turbine since the flow source switched from a saturated vapor from the separator to a lower enthalpy water-vapor mixture from the main flow line. Therefore, in order to avoid pressure excursions and an uncontrolled significant temperature drop at the turbine throttle, the valve controlling flow to the turbine directly from the main flow line had to be opened very slowly, the firing rate had to be increased, and the separator outlet valve closed to slowly transfer the source of turbine steam from the separator to the main flow line. This, of course, resulted in a considerable expenditure of time and energy, and a considerable sophistication of controls.

Also, in these latter arrangements, when vapor formed in the separator in response to a startup firing rate input, the vapor, in addition to flowing to the turbine, was routed to other areas of the system such as high-pressure heaters and/or the condenser until a percentage of the final turbine load was achieved. Therefore, these arrangements required the use and operation of several valves which added to the labor and costs in the operation of the system.

Although it has been suggested to provide a separator directly in the main flow line, these arrangements have proven to be costly due to the fact that a relatively large, thick-walled separator, and associated components, have to be used. Also, the vapor initially forming in the separator is passed in a circuit bypassing the finishing superheater and the turbine during startup, after which the flow is switched to the superheater and turbine, which also requires a control system utilizing a number of valves.

In copending application Ser. No. 713,313, assigned to the same assignee as the present invention, a startup system is disclosed in which the vapor generating section operates at substantially constant pressure during startup with a pressure reducing station being provided downstream of furnace circuits which controls the fluid pressure upstream. The pressure reducing station includes one or more small bore tubes and a conduit having a reducing valve therein, all arranged in parallel flow relationship. A plurality of separators are provided in the main flow path which receive the fluid from the pressure reducing station and separate same into a liquid and a vapor with the liquid being drained from the system through a bypass circuit located externally of the main flow circuit. In this manner the use of a flash tank in a bypass circuit is eliminated yet the turbine is able to be smoothly loaded at pressures and temperatures that constantly and gradually increase. Also, the above is achieved without the use of an appreciable number of valves.

In this arrangement, the throttle pressure, i.e., the pressure of the fluid presented to the turbine was ramped, i.e., increased proportionally with load, to a maximum value at a 25% load, after which the bypass drain from the separators was shut off. However, the operational advantages of this type of throttle pressure ramping are minimal especially in connection with turbines having sequential partial arc valve control, for several reasons. First of all, although sequential partial arc admission to the turbine as used therewith minimizes throttling losses, lower turbine first stage outlet temperatures result when only 25% of turbine control valves are opened as was true in that application. Large thermal changes within the turbine are therefore experienced during loading and uploading. Therefore, the time required to achieve hot starts for the turbine and steam generator is relatively high. In addition, when loading to 25% load at full pressure with turbine control valves 25% open, the enthalpy of main steam to the turbine is lower than that which can be achieved when 25% load plateau is reached at a lower throttle pressure. As a result, the cycle efficiency and the ability of the system to pickup load at an increased rate are less than achievable with ramping pressure to higher load plateaus.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide a method for starting up a vapor generator which does not require the use of bypass circuitry incorporating a flash tank.

It is a further object of the present invention to provide a method of the above type in which a plurality of separators are utilized which together operate in a manner to permit the turbine to be smoothly loaded at pressures and temperatures that constantly and gradually increase.

It is a still further object of the present invention to provide a method of the above type in which vapor initially forming in the separators is immediately passed in the main vapor circuit containing the superheater section and the turbine to eliminate the controls and valves required to initially route the vapor elsewhere.

It is a still further object of the present invention to provide a method of the above type in which time for effecting hot starts is reduced and load pickup ability and the cycle efficiency are increased.

It is a more specific object of the present invention to provide a method of the above type in which the throttle pressure attains a maximum value at an increased load to the turbine which load is in excess of that load at which the liquid drain from the separators is shut out of the system.

It is a still more specific object of the present invention to provide a method of the above type in which the throttle pressure is increased in proportion to the load demand for the turbine generator until the latter reaches a predetermined % of full load.

It is a still more specific object of the present invention to provide a method of the above type in which the throttle pressure is increased in proportion to the load demand for the turbine generator until the latter reaches approximately 60% of full load with turbine valves 50% open.

Toward the fulfillment of these and other objects, the method of the present invention includes the steps of passing fluid through a vapor generator furnace section at a predetermined fluid flow rate, and establishing a firing rate in said furnace section to apply heat to said fluid while maintaining turbine control valves at a predetermined percent open. The pressure of the fluid is controlled as it exits from said furnace section with the fluid flow rate being maintained at a predetermined level while the firing rate in the furnace section is increased. When the firing rate reaches a predetermined level, the liquid drain line from the separators located downstream of the pressure reducing station is closed. After the firing rate reaches the predetermined level, it is increased with fluid flow rate until turbine throttle pressure reaches a predetermined level. When the throttle pressure reaches the predetermined level, further loading of the turbine to full load is achieved by opening turbine control valves and proportionally increasing the fluid flow rate and the firing rate.

BRIEF DESCRIPTION OF THE DRAWINGS

The above brief description, as well as further objects, features, and advantages, of the present invention will be more fully appreciated by reference to the following detailed description of a presently preferred but nonetheless illustrative embodiment in accordance with the present invention when taken in connection with the accompanying drawings, wherein:

FIG. 1 is a schematic representation of a power plant incorporating the system of the present invention;

FIG. 2 is a partial sectional, partial schematic view of the vapor generating section of the system of the present invention;

FIG. 3 is a schematic perspective view illustrating the furnace circuit used in the system of the present invention;

FIG. 4 is a vertical cross-sectional view of a separator used in the system of the present invention;

FIG. 5 depicts the flow circuit included in the pressure reducing station of the system of the present invention;

FIGS. 6-10 are a series of schematic diagrams, similar to FIG. 1 and illustrating the various operational modes of the system of the present invention; and

FIG. 11 is a pair of operational curves derived in accordance with the system of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1 of the drawings, there is depicted the main fluid circuit of the system of the present invention, which includes an economizer 10 which receives a heat exchange fluid, such as water, and transfers same to a furnace section 12 which is adapted to convert the water to steam in a manner to be described. A pressure reducing station 14 is located downstream from the furnace section 12, and a separating station 16 is in direct flow connection with the outlet of the pressure reducing station. A primary superheater 18 is located downstream of the separating station 16, and, in turn, is connected to a finishing superheater 20. A high pressure turbine 22 receives fluid from the finishing superheater 20 after it passes through a stop valve 24, and the exhaust flow from the high pressure turbine 22 is reheated in a reheater 26 before being transmitted to a low pressure turbine 28. The economizer 10, the furnace section 12, the

superheaters

18 and 20, and the reheater 26 are all part of a vapor generating section which will be described in detail later.

Also included in the main flow path is a condenser 30 which receives the exhaust flow from the low pressure turbine 28 and which includes a hotwell 32. Between the hotwell 32 and the economizer 10, the main flow path includes a demineralizer 34 which receives the condensate from the hotwell 32 under the force of a pump 36, a series of low pressure heaters, shown in general by the reference numeral 38, and a deaerator 40 which transmits the flow to a feedwater pump 42. The water is pressurized in the feedwater pump 42 and transmitted to the tube sides of two

high pressure heaters

44 and 46, and from there back to the economizer 10 to complete the main flow circuit.

It is understood that the connections between the above-mentioned sections in the main flow circuit which are shown schematically in the drawings are achieved by fluid circuitry in the form of conduits, tubes, risers, headers, etc., to transfer the heat exchange fluid throughout the various sections.

Other components associated with the main flow circuit include a pair of

auxiliary steam lines

47a and 47b connected in the main flow circuit immediately upstream and downstream, respectively, of the primary superheater 18 and connected to

headers

48a and 48b, respectively. The

headers

48a and 48b can be connected to one or more of several components in the system, such as the deaerator 40, the

heaters

38, 44, 46, and the seals and/or the feed pumps of the

turbines

22 and 28, to supply steam from the main flow circuit to their components. It is understood that suitable valving can be disposed in the

lines

47a and 47b to control the flow of the steam from the main flow circuit to the

headers

48a and 48b, respectively.

Other associated components include a spray station 49 located in the circuit between the primary superheater 18 and the finishing superheater 20, a turbine stop valve bypass 50 connected in parallel with the turbine stop valve 24 between the finishing superheater 20 and the high pressure turbine 22, and a turbine control valve 51 located immediately upstream of the high pressure turbine 22. Although only one turbine control valve 51 is shown for the convenience of presentation it is understood that a plurality of such valves can be provided in parallel as needed.

The separating station 16 includes a plurality of separators which will be described in detail later and which operate to receive a mixture of vapor and water and separate the vapor from the water. In this context, a water flow circuit, including a drain line 52, connects the water outlets of each of the separators to a drain collecting header 54 from which the water passes through an isolating valve 56 and to control

valves

58 and 60 arranged in parallel. A level control unit 62 is responsive to level changes in the separators in a manner to be described, for controlling the operation of the

control valves

58 and 60 to maintain predetermined water levels in the separators.

Valves

64, 66, and 68 are disposed in the above-mentioned water flow circuit to selectively direct the water from the

control valves

58 and 60 to the condenser 30, the deaerator 40, and to the high pressure heater 46, respectively.

Other ancillary fluid flow circuits include

lines

70a and 70b connecting the output of the high pressure heater 46 to the hotwell 32 and the deaerator 40, respectively, under the control of

valves

72a and 72b, respectively; and a line 74 connecting the generator side of the stop valve 24 to the condenser 30 under the control of a valve 76 for the purposes of providing a drain for the main fluid circuit to the condenser 30.

Reference is now made to FIG. 2 which depicts the above-mentioned vapor generating section of the present invention which includes several of the above-mentioned components in greater detail. In particular, the vapor generating section is referred to in general by the reference numeral 80 and includes the furnace section 12 which is formed by front and

rear walls

82 and 84, respectively, and a pair of sidewalls 88 (one of which is shown in FIG. 2) which extend between the front and rear walls to define an enclosure. The lower portions of the front wall 82 and the rear wall 84 are sloped inwardly to form a hopper section 92. It is understood that each of the

walls

82, 84, and 88 are made up of a plurality of vertically extending tubes having continuous fins extending outwardly from diametrically opposed portions thereof, with the fins of adjacent tubes being connected together to form an airtight structure.

The front wall 82 and both sidewalls 88 form continuous panels extending vertically from the hopper portion 92 to a roof 94 which is also formed of a plurality of tubes arranged in the above manner. The upper portion of the rear wall 84 is configured in a manner to be described later so as to define a plurality of openings which, together with the roof 94, define a gas exit 96 which leads to a vestibule 98 in gas flow communication with a downwardly extending convection zone 100 having an outlet 102. The vestibule 98 and the convection zone 100 house the economizer 10, the primary superheater 18, the finishing superheater 20, and the reheater 26, all of which are in the form of a plurality of tubes adapted to receive the heat exchange fluid.

A plurality of

burners

104 and 106 are disposed in the front and

rear walls

82 and 84, respectively, immediately above the hopper section 92, with the burners being arranged in several vertical rows of four burners per row.

As a result of the above, the flow of gases in the vapor generating section is upwardly through the furnace section 12 and through the gas exit 96 into the vestibule 98 and downwardly in the convection zone 100 to the outlet 102. It is understood that an air heater (not shown) is connected to the outlet 102 for effecting a heat exchange between the hot exhaust gases and incoming air for the burners in a conventional manner.

The details of the particular arrangement of the furnace section 12 are better depicted in FIG. 3. In particular, the upper portion of the rear wall 84 has a branch portion 84a which is formed by bending a selected number of tubes from the upper portion of the rear wall 84 to provide adequate spacing between some of the tubes in both of the

wall

84 and 84a to define the exit 96 and permit the gases to pass from the vestibule portion 98 into the convection zone 100. A plurality of spaced parallel division walls 110 extend within the upper portion of the furnace enclosure with their lower portions being bent to penetrate the front wall 82 at a location above the burners 104, with the penetrating end portions of the division walls being connected to an inlet header 112.

The fluid flow circuit through the vapor generating section will be described in connection with FIGS. 2 and 3. In particular, feedwater from an external source (not shown) is passed to the tubes of the economizer 10 where it is heated by the gases passing over the latter tubes before exiting from the outlet 102. The heated feedwater from the economizer 10 is then passed via a line 113 (FIG. 2) to the inlet header 112 of the division walls 110 where it flows upwardly through the tubes of the walls to a plurality of outlet headers 114, and, via a header 116 and a downcomer 118 to an inlet header 120 which is in registry with the lower ends of the tubes of the front wall 82, as shown in FIGS. 2 and 3. An outlet header 122 is in registry with the upper end of the tubes of the wall 82 for receiving the water after it passes through the latter wall. A downcomer 124 connects the outlet header 122 to inlet headers 126 which register with the lower ends of the tubes of both sidewalls 88 with the downcomer being branched to provide equal flow to both inlet headers. The fluid flow is thus transmitted upwardly through both sidewalls 88 where it is collected in headers 128 registering with the upper ends of the tubes of the latter walls. The fluid is then transferred, via a header 130 and a downcomer 132 to an inlet header 134 registering with the lower ends of the tubes of the rear wall 84. The fluid then flows upwardly through the tubes of both the rear wall 84 and the branch wall 84a in a parallel fashion before it is respectively passed, via outlet headers 136 and 136a, respectively, to an inlet header 138 connected to the tubes forming the roof 94, for further treatment that will be described later.

As a result of the foregoing, the water flows upwardly through the walls of the furnace 12 in essentially four vertically oriented flow passes connected in series--a first pass through the division walls 110, a second pass through the front wall 82, a third pass through the sidewalls 88, and a fourth pass through the rear wall 84. As a result of this type of multipass flow, the furnace operates at constant pressure during startup, as will be described in detail later.

FIG. 4 depicts, in detail, one of the separators used in the separating station 16 in the main flow circuit. The separator is referred to in general by the reference numeral 140 and includes an upright cylindrical shell 142 through which a riser pipe 144 extends in a coaxial relationship. The riser pipe 144 has an end portion 144a extending from the lower end of the shell 142 which is adapted for receiving fluid from the pressure reducing station 14. A cap 146 extends over the upper end of the pipe 144 and a plurality of slots 148 are formed through the upper wall portion of the pipe near the latter end. A plurality of substantially spiral-shaped arms 150 are connected to the pipe 144 in registry with the slots 148 with the free ends of the arms being open to permit fluid to discharge therefrom.

A cylindrical, open-ended, skirt 152 extends within the shell 142 and around the upper portion of the riser pipe 144 in a coaxial relationship therewith, with the inner wall of the skirt being spaced a small distance from the free ends of the arms 150. The skirt 152 is supported relative to the shell 142 in the position shown by spacers 151 and a plurality of set screws 153 extending through the shell and engaging the skirt.

A drip ring 154 is disposed in the upper portion of the shell 142 above the arms 150, and a cup-shaped thermal sleeve 156 extends over the lower end portion 144a of the riser pipe 144 to define an annular passage in communication with an auxiliary drain 158.

A vapor outlet nozzle 160 is provided at the upper end portion of the shell 142 and a radially extending drain water outlet 162 is provided near the lower end portion of the shell. Also, the shell 142 is provided with a high level connection 164 and a low level connection 166 disposed near the upper and lower end portions of the shell, respectively, for the purpose of maintaining predetermined water levels in the shell 142, as will be described later.

As a result of the above, when the fluid entering the end portion 144a of the riser pipe 144 from the pressure reducing station 14 is in the form of a vapor-water mixture, it passes upwardly in the riser pipe and then radially outwardly from the pipe through the slots 148 and into the arms 150 where it will be directed tangentially against the inner wall of the skirt 152. This creates a vortex, or whirling stream, of fluid with the resulting centrifugal forces causing the vapor portion of the fluid to travel away from the inner wall of the skirt 152 and towards the center of the whirling stream, and pass upwardly by virtue of its buoyance into the upper portion of the shell 142, from which it exits, via the outlet 160. The liquid, or water, portion of the mixture in the whirling stream collects on and flows down the inner wall of the skirt 152 until it falls off the wall, collects in the lower end of the shell 142 and drains from the connection 162 for passage to and through line 52 of the fluid circuit, as previously mentioned in connection with FIG. 1.

As also shown in FIG. 1, the pressure reducing station 14 includes five

flow lines

166, 167, 168, 170, and 172, connected in parallel. Line 166 has an on-off valve 174 connected therein,

lines

167 and 168 have pressure reducing, or throttling,

valves

175 and 176, respectively, connected therein and

lines

170 and 172 have on-off

valves

178 and 180, respectively, connected therein, to selectively reduce the fluid pressure to the separating station 16 during initial startup, as will be explained in detail later.

As shown in FIG. 2, the flow line 166 is in the form of a conduit connected to an outlet header 165 in flow communication with the tubes forming the roof 94, with one end of the conduit registering with a downcomer 182.

The specific arrangement of the conduit 166 along with the details of the other components of the pressure reducing station 14 are shown in FIG. 5. In particular, the flow line 167 is in the form of a bypass conduit connected to the conduit 166 and to the downcomer 182, and the flow line 168 is in the form of a bypass conduit connected to the conduit 166 and the conduit 167. Each of the

flow lines

170 and 172 is in the form of relatively small bore tube with a high friction pressure drop when compared to the other flow conduits of the system. Each of the

tubes

170 and 172 connects the conduit 166 with the conduit 167 and functions to increase the pressure drop across the pressure reducing station as the temperature and flow of the fluid increase during startup. It is noted from the foregoing that the

conduits

166, 167 and 168 and the

tubes

170 and 172 are, in effect, connected in parallel with their equivalent parallel connections being shown in FIG. 1.

The

valves

174, 178, and 180 associated with the conduit 166 and the

flow tubes

170 and 172, respectively, are in the form of on-off valves for selectively permitting fluid flow through the latter lines. The valve 174 is closed when the generator is initially fired but is opened during startup as will be described later. The

valves

178 and 180 are opened initially during starting and remain in an open position during operation, but can be shut off in the event the system goes off line or must be shut down for cleaning or the like. The

valves

175 and 176 associated with the

conduits

167 and 168, respectively, are reducing valves which can be sequentially moved in incremental steps from a normally closed position during startup to a wide open position during normal operation to control the fluid pressure at the furnace outlet. The reducing

valves

175 and 176 can be operated automatically in sequence in response to furnace pressure with the valve 175 opening partially only after valve 176 is substantially opened. The stop valve 174 completely opens in response to a substantial opening of the valve 175.

A plurality of conduits 190 connect the downcomer 182 to the end portions 144a of the risers 144 of a plurality of separators 140. It is understood that several of the separators 140 have been omitted from the drawings in the interest of brevity. Although also not shown in the drawings, it is also understood that another flow circuit identical to the one just described, connects the downcomer 182 to another series of separators 140.

The vapor outlets 160 of the separators 140 are connected to an inlet header 192 for the primary superheater 18 as shown in FIG. 2 for supplying the vapor from the separators to the superheater. As previously discussed, the water outlets 162 of the separators 140 are connected, via a line 52 to the drain collecting header 54.

The basic operation of the system of the present invention is better described with reference to FIGS. 6-10 which are similar to FIG. 1 but shown by means of relatively heavy lines and shading of the various components, the actual flow paths through the circuitry of the system during various operational stages; and with reference to FIG. 11 which depicts the variations of furnace pressure and the throttle pressure to the superheaters and high pressure turbine throughout the above-mentioned stages of operation and summarizes the pressure variances discussed in connection with FIGS. 6-10. In particular, and with reference to FIG. 6, the system is initially flushed by actuating the feedwater pump 42 and opening the

valves

178 and 180 to establish a feedwater pumping rate of approximately 15% of full load which routes the water through the economizer 10, the walls of the furnace section 12, the

valves

178 and 180 and the

tubes

170 and 172, with the latter functioning by virtue of inherent resistance to maintain the upstream furnace circuit pressure at a value of approximately 1000 psi. The

valves

66 and 68 are closed and the valve 64 opened so that the water draining from the separators 140 passes through the line 52, the header 54, and the

valves

56, 58 and 60, to the condenser 30, via the valve 64. In this manner, cycle water clean-up can be accomplished by routing the flow through the demineralizer 34. Since no vapor is generated at this stage, there is no flow through the vapor flow circuit extending from the separators 140. The

control valves

58 and 60 will maintain normal water level in separators 140 is response to the level control unit 62.

With reference to FIG. 7, when satisfactory cation conductivity of the water is achieved the

burners

104 and 106 are lit at approximately 10-15% of their full load firing rate and the temperature of the fluid entering the pressure reducing station 14 is raised over a period of time to approximately 450° with the

tubes

170 and 172 allowing the furnace circuit pressure to reach approximately 1200 psi.

The feedwater pumping rate is increased to 25% of full flow and the firing rate increased accordingly which causes the reducing valve 176 to open as necessary to control the outlet pressure from the furnace 12 to approximately 3600 psi. It should be understood that furnace outlet pressure may be controlled to a constant or variable set point pressure. The valve 64 is closed and the

valves

66 and 68 are opened so that drain water from the separators 140 is routed through the line 52, the header 54, and to the deaerator 40 and the high pressure heater 46 under control of the

valves

66 and 68, respectively. The steam separated in the separators 140 as a result of the above-mentioned increased temperature is routed directly to and through the

superheaters

18 and 20 and to the turbine stop valve 24 where it drains, through the line 74, into the condenser 30.

Referring to FIG. 8, the valve 76 is closed, and the throttle pressure, i.e., the pressure downstream of the pressure reducing station 14, is then raised to 500 psi by further increasing the firing rate of the

burners

104 and 106. The turbine stop bypass valve 50 is opened to direct steam into the high pressure turbine 22 which is brought up to speed, synchronized and initially loaded to approximately 3% of full load. The turbine load is then increased to 8% of full load while the 500 psi throttle pressure is maintained by increased firing rate, with the spray station 49 controlling the final steam temperature to turbine 22. In this mode, the water flow from the separators 140 is identical to that discussed in the previous mode.

The turbine load is then increased until it approaches 25% of full load with the turbine control valve 51 approximately 50% open and the throttle pressure is ramped, or increased from 500 psi to 1500 psi in proportion to the load demand increase by control of the firing rate at the constant 25% feedwater pumping rate to achieve the operation shown in FIG. 9. In this mode, the turbine bypass valve 50 is shut off and the steam flow is through the turbine stop valve 24. As the throttle pressure approaches 1500 psi a separator pressure error override modifies the level control unit 62 signal to control

valves

58 and 60 when low level is indicated. In this manner proper operation of

valves

58 and 60 is assured even as the level control signal becomes indefinite or erratic.

As the load approaches 25%, the throttling valve 176 of the pressure reducing station 14 completely opens and the larger control valve 58 of the separating station 16 closes with later sequential closing of the small control valve 60. At 25% load both

valves

58 and 60 are closed removing the bypass water drain circuit, including line 52 from service, as shown in FIG. 10.

It is to be understood that ramping to various percentages of full load (load plateaus) is contemplated, and depending on system design parameters such as minimum flow requirements for furnace circuits corresponding changes will be made to the point in load at which the bypass drain line will be taken out of service.

As the turbine load is increased above 25%, the throttling valve 175, which responds to a predetermined percentage of opening of the valve 176, begins to open to enable the ramping of the throttle pressure to continue from the 1500 psi value in response to further increases in the firing rate and the water flow rate. This continues until a maximum throttle pressure of 3600 psi is attained at 60% load.

As the turbine load is increased above 60%, the stop valve 174 at the pressure reducing station 14 is opened in response to a permissive signal generated when valve 175 is greater than a predetermined percent open position and vapor at the full pressure of 3600 psi from the furnace section 12 passes through the pressure reducing station, the separators 140, the

superheaters

18 and 20 and to the high pressure turbine 22, with the spray station 49 in service for transient control of final steam temperature.

Further load increases would be effected at the constant throttle pressure of 3500 psi by further opening of one or more of the turbine control valves represented by valve 51 and the firing rate and water flow adjusted as needed to add heat to the system in accordance with the particular load requirements.

It is thus seen that the method of the present invention enables a quick and efficient startup to be achieved with a minimum of control functions. For example, the

small bore tubes

170 and 172 function to control the pressure of the cold fluid during startup without the need for costly valves and without requiring the use and resultant excessive wear of the

valves

174, 175 and 176. Also, since the level in the separators 140 in the arrangement of the present invention determines the division point between water and steam circuits during startup, the system and method of the present invention enables the turbines to be smoothly loaded at optimum pressures and temperatures that can be constantly and gradually increased, without the need of boiler division valves or external bypass circuitry for steam dumping. Also, according to the method of the present invention, operation can be continuous at very low loads with a minimum of heat loss to the condenser.

Further the increased capacity of the pressure reducing station, afforded by the

valves

175 and 176 enables the maximum throttle pressure to be attained at 60% load with turbine control valves at 50% open after the separator water drain has been removed from the circuit at a lower load plateau. Ramping to other load plateaus is also contemplated with the system when various other turbine control valve open settings are employed, i.e, ramping to 100% load with turbine control valves fully open. This enables more optimum throttle steam conditions to be provided to the turbine to limit thermal changes within the turbine during loading and unloading. Also, a more uniform thermal gradient for the turbine is achieved during load changes and, in addition, the turbine and steam generator hot start times are reduced. Still further, the latter feature increases steam enthalpy to the turbine during startup and loading and improves the cycle efficiency and the ability of the system to pickup load at an increased rate.

It can be appreciated that the method of the present invention can operate in a cyclic mode, such as, for example, reduction to house load daily and/or weekly shutdowns and restarts.

It is understood that several variations in the foregoing can be made without departing from the scope of the invention. For example, the number of tubes similar to

tubes

170 and 172 and the number of conduits similar to

conduits

167 and 168 in the pressure reducing station 14 can be increased as necessary. Furthermore, it should be understood that the load plateau to which the throttle pressure extends is related to the precent that the turbine throttle valve means are open. In the particular embodiment hereinbefore described in detail, with the turbine valves set at 50% open during the turbine throttle pressure ramp, the ramp extended to a 60% load plateau. Ramping to other load plateaus, or percentages of full load, can be achieved by changing the percent that the turbine valves are open. It should also be understood that when a plurality of valves are arranged for partial arc admission, the open valves are preferably fully open to minimize throttle losses.

Also, rather than utilize an additional valve 175 and conduit 167 the valve 174 can be modified to incorporate a pilot valve in the main plug and the control system modified to adjust the pilot valve opening as the aforementioned throttle pressure ramping takes place. This pilot valve would open in response to opening of the valve 176, and when the throttle pressure achieves 3600 psi at 60% load with turbine control valves at 50% open the pilot valve would be fully open and the main valve portion of the valve 174 would open as discussed above. The pilot valve would thus be functionally equivalent to the valve 175.

It is also understood that other variations of the specific construction and arrangement of the system and method disclosed above can be made by those skilled in the art without departing from the invention as defined in the appended claims.

Claims

What is claimed is:

1. A method of operating a vapor generating system for use in a power plant having turbine control valve means, a steam turbine and a condenser connected in a main flow circuit in a series flow relationship; said method comprising the steps of passing fluid through a vapor generator furnace section at a pedetermined percentage of full load flow rate, establishing a firing rate in said furnace section to apply heat to said fluid for converting said fluid to a vapor, separating the vapor portion from the liquid portion of said fluid in said main flow circuit, passing said liquid portion of said fluid in a bypass circuit externally of said main flow circuit, passing said vapor portion through said main flow circuit while increasing said firing rate to a predetermined percentage of full load firing rate and maintaining said predetermined percentage of full load flow rate to increase the throttle pressure of said fluid to said turbine to a value less than a predetermined maximum value, and then increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section in a manner to control the throttle pressure of said fluid to said turbine in proportion to the load demand on said turbine until said throttle pressure attains said predetermined maximum value and the load on said turbine reaches a predetermined percentage of full load.

2. The method of claim 1 further comprising the steps of maintaining said turbine control valve means at a predetermined percent open and then opening said turbine control valve means beyond said predetermined percent open and increasing said fluid flow rate and said firing rate so as to increase the flow of fluid to said turbine in proportion to further load demand on said turbine, while maintaining said predetermined maximum throttle pressure to said turbine.

3. The method of claim 2 wherein said step of maintaining said turbine control valve means at a predetermined percent open comprises fixing said turbine control valve means at 50% open, and wherein said turbine load of a predetermined percentage of full load is approximately 60% of full load.

4. The method of claim 3 wherein said throttle pressure attains said predetermined maximum value as the load on said turbine reaches approximately 60% of full load.

5. The method of claim 3 wherein said throttle pressure is maintained at said predetermined maximum value at all load demands on said turbine in excess of 60%.

6. The method of claim 4 wherein said predetermined maximum value of said throttle pressure is equal to the pressure of said fluid as it exits from the furnace section less any pressure drop in said flow circuit.

7. The method of claim 1 wherein said step of controlling said pressure exiting said furnace section is effected by sequentially opening a plurality of pressure reducing valves connected in parallel downstream of said furnace section and upstream of said turbine.

8. The method of claim 1 wherein said predetermined percentage of full load firing rate approximately corresponds to said percentage of full load flow rate of said fluid.

9. The method of claim 1 further comprising the steps of loading said turbine before said first step of increasing.

10. A method of operating a vapor generating system for use in a power plant having turbine control valve means, a steam turbine and a condenser connected in a main flow circuit in a series flow relationship; said method comprising the steps of passing fluid through a vapor generator furnace section at a predetermined percentage of full load flow rate, establishing a firing rate in said furnace section to apply heat to said fluid for converting said fluid to a vapor, separating the vapor portion from the liquid portion of said fluid in said main flow circuit, passing said liquid portion of said fluid in a bypass circuit externally of said main flow circuit, passing said vapor portion through said main flow circuit while increasing said firing rate to a predetermined percentage of full load firing rate, disconnecting said bypass circuit from said main flow circuit after said firing rate reaches said predetermined percentage of full load firing rate, and then increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section in a manner to control the throttle pressure of said fluid to said turbine in proportion to the load demand on said turbine until the load on said turbine reaches a predetermined percentage of full load.

11. The method of claim 10 further comprising the steps of maintaining said turbine control valve means at a predetermined percent open and then opening said turbine control valve means beyond said predetermined percent open and increasing said fluid flow rate and said firing rate so as to increase the flow of fluid to said turbine in proportion to further load demand on said turbine, while maintaining said predetermined maximum throttle pressure to said turbine.

12. The method of claim 11 wherein said step of maintaining said turbine control valve means at a predetermined percent open comprises fixing said turbine control valve means at 50% open, and wherein said step of increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section comprises increasing said fluid flow rate and said firing rate to approximately 60% of the respective full load rates.

13. The method of claim 11 wherein said throttle pressure attains a maximum value as the load demand on the turbine reaches approximately 60% of full load.

14. The method of claim 13 wherein said throttle pressure is maintained at said maximum value at all load demands on said turbine in excess of 60% of full load.

15. The method of claim 13 wherein said maximum value of said throttle pressure is equal to the pressure of the fluid exiting from the furnace section less any pressure drops in said flow circuit.

16. The method of claim 10 wherein said step of controlling the pressure of said fluid as it exits from the furnace section is effected by sequentially opening a plurality of pressure reducing valves connected in parallel downstream of said furnace section and upstream of said turbine.

17. The method of claim 10 wherein said predetermined percentage of full load firing rate approximately corresponds to said percentage of full load flow rate of said fluid.

18. The method of claim 10 further comprising the steps of loading said turbine before said first step of increasing.

19. A method of operating a vapor generating system for use in a power plant having turbine control valve means, a steam turbine and a condenser connected in a main flow circuit in a series flow relationship; said method comprising the steps of passing fluid through a vapor generator furnace section at a predetermined percentage of full load flow rate, establishing a firing rate in said furnace section to apply heat to said fluid for converting said fluid to a vapor, separating the vapor portion from the liquid portion of said fluid, passing said liquid portion of said fluid in a bypass circuit externally of said main flow circuit, applying a load to said turbine, then increasing said firing rate to a predetermined percentage of full load firing rate while maintaining said predetermined percentage of full load flow rate to increase the throttle pressure of said fluid to said turbine to a value less than a predetermined maximum value, and then increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section in a manner to control the throttle pressure of said fluid to said turbine in proportion to the load demand on said turbine until said throttle pressure attains said predetermined maximum value and the load on said turbine reaches a predetermined percentage of full load.

20. The method of claim 19 wherein said predetermined percentage of full load firing rate approximately corresponding to said percentage of full load flow rate of said fluid.

21. The method of claim 19 further comprising the steps of maintaining said turbine control valve means at a predetermined percent open and then opening said turbine control valve means beyond said predetermined percent open and increasing said fluid flow rate and said firing rate so as to increase the flow of fluid to said turbine in proportion to further load demand on said turbine, while maintaining said predetermined maximum throttle pressure to said turbine.

22. The method of claim 21 wherein said step of maintaining said turbine control valve means at a predetermined percent open comprises fixing said turbine control valve means at 50% open, and wherein said step of increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section comprises increasing said fluid flow rate and said firing rate to approximately 60% of the respective full load rates.

23. The method of claim 21 wherein said throttle pressure attains a maximum value as the load demand on the turbine reaches approximately 60% of full load.

24. The method of claim 23 wherein said throttle pressure is maintained at said maximum value at all load demands on said turbine in excess of 60% of full load.

25. The method of claim 23 wherein said maximum value of said throttle pressure is equal to the pressure of the fluid exiting from the furnace section less any pressure drops in said flow circuit.

26. The method of claim 19 wherein said step of controlling the pressure of said fluid as it exits from the furnace section is effected by sequentially opening a plurality of pressure reducing valves connected in parallel downstream of said furnace section and upstream of said turbine.

27. A method of operating a vapor generating system for use in a power plant having turbine control valve means, a steam turbine and a condenser connected in a main flow circuit in a series flow relationship; said method comprising the steps of passing fluid through a vapor generator furnace section at a predetermined percentage of full load flow rate, establishing a firing rate in said furnace section to apply heat to said fluid for converting said fluid to a vapor, separating the vapor portion from the liquid portion of said fluid passing said liquid portion of said fluid in a bypass circuit externally of said main flow circuit, applying a load to said turbine, then increasing said firing rate to a predetermined percentage of full load firing rate, disconnecting said bypass circuit from said main flow circuit after said firing rate reaches said predetermined percentage of full load firing rate, and then increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section in a manner to control the throttle pressure of said fluid to said turbine in proportion to the load demand on said turbine until the load on said turbine reaches a predetermined percentage of full load.

28. The method of claim 27 wherein said predetermined percentage of full load firing rate approximately corresponds to said percentage of full load flow rate of said fluid.

29. The method of claim 27 further comprising the steps of maintaining said turbine control valve means at a predetermined percent open and then opening said turbine control valve means beyond said predetermined percent open and increasing said fluid flow rate and said firing rate so as to increase the flow of fluid to said turbine in proportion to further load demand on said turbine, while maintaining said predetermined maximum throttle pressure to said turbine.

30. The method of claim 29 wherein said step of maintaining said turbine control valve means at a predetermined percent open comprises fixing said turbine control valve means at 50% open, and wherein said step of increasing said fluid flow rate and said firing rate while controlling said pressure of said fluid exiting from said furnace section comprises increasing said fluid flow rate and said firing rate to approximately 60% of the respective full load rates.

31. The method of claim 29 wherein said throttle pressure attains a maximum value as the load demand on the turbine reaches approximately 60% of full load.

32. The method of claim 31 wherein said throttle pressure is maintained at said maximum value at all load demands on said turbine in excess of 60% of full load.

33. The method of claim 31 wherein said maximum value of said throttle pressure is equal to the pressure of the fluid exiting from the furnace section less any pressure drops in said flow circuit.

34. The method of claim 27 wherein said step of controlling the pressure of said fluid as it exits from the furnace section is effected by sequentially opening a plurality of pressure reducing valves connected in parallel downstream of said furnace section and upstream of said turbine.